UNIVERSITI PUTRA MALAYSIA

NURHAIZA SHAHRIR

FK 2013 7

DEVELOPMENT AND VERIFICATION OF PREDICTIVE MAINTENANCE SYSTEM IN A SOLAR CELL MANUFACTURING

INDUSTRY

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DEVELOPMENT AND VERIFICATION OF PREDICTIVE

MAINTENANCE SYSTEM IN A SOLAR CELL MANUFACTURING

INDUSTRY

By

NURHAIZA SHAHRIR

Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Fulfillment of the Requirements for the Degree of Master of Science

January 2013

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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in

fulfillment of the requirement for the degree of Master of Science

DEVELOPMENT AND VERIFICATION OF PREDICTIVE

MAINTENANCE SYSTEM IN A SOLAR CELL MANUFACTURING

INDUSTRY

By

NURHAIZA SHAHRIR

January 2013

Chairman : Mohd Khairol Anuar Mohd Ariffin, PhD.

Faculty : Engineering

Manufacturing industries need to find the best preventive maintenance strategy

during their planning and scheduling. When a machine is taken down for

maintenance, it does not produce a product for the company which means

production is interrupted thus incurring loss to the company. Therefore, downtime

for services needs to be minimized. Preventive Maintenance is a service being done

by qualified personnel to ensure that the equipment is always in a good and safe

operating condition.

Preventive Maintenance is a set of activities taken based on a planned schedule

either by time or a condition to prevent permanent or lengthy breakdowns. Example

of a Preventive Maintenance are like changing lead screw bearing every year or

servicing filter at every 50,000 running hours. Usually preventive maintenance is

scheduled based on equipment vendor’s recommendation. Through experience

running the equipment, engineers will be knowledgeable to adjust their schedule

based on the nearest actual lifetime which is based on the history or record.

Solar Cell manufacturing is facing high unscheduled downtime. The aim of this

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project was to develop a Predictive Maintenance System in a solar cell

manufacturing environment. A Predictive Maintenance System in a solar cell

manufacturing industry should reduce its equipment unscheduled downtime

because not all types of problems can be prevented by using a scheduled

maintenance alone. The machine operation involves process parameters and human

interventions. Thus the preventive actions need to be taken before its breakdown.

Nevertheless, having a scheduled preventive maintenance is the least a

management should implement to reduce the machine breakdown if there is no

form of other solution.

This research had proposed to use a Continuous Improvement Program method by

Vannest and Wassenhove which was developed in 1995 which aims to reduce

downtime. This research then, had proposed a streamline and comprehensive tools

for this continuous improvement program which are the use of Pareto Analysis and

FMEA before starting any improvement activity. This research had also developed

an improvised diagnostic method of Predictive Maintenance System that was from

Groba et al. in year 2007. The Predictive Maintenance System that was developed

from this research had used diagnostic method through use of failure limit(s) and its

threshold limit(s).

This Predictive Maintenance System was then developed and tested in one of solar

cell manufacturing company in Peninsular Malaysia which had just operated in less

than 5 years. It was verified that this Predictive Maintenance System had cause a

reduction of unscheduled downtime of more than 23% for Deposition and

Diffusion equipments in one Solar Cell manufacturing company. This research had

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successfully developed a streamline and comprehensive tools for Continuous

Improvement Program which integrates with Predictive Maintenance System using

threshold Limit(s) and failure Limit(s).

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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai

memenuhi keperluan untuk Ijazah Master Sains

PEMBENTUKAN DAN PENGESAHAN SISTEM PENYELENGGARAAN

JANGKAAN DI INDUSTRI PEMBUATAN SEL SURIA.

Oleh

NURHAIZA SHAHRIR

Januari 2013

Pengerusi : Mohd Khairol Anuar Mohd Ariffin , PhD.

Fakulti : Kejuruteraan

Industri pembuatan perlu mencari strategi penyelenggaraan pencegahan yang

terbaik. Apabila sebuah mesin diambil untuk penyelenggaraan pencegahan, ia tidak

menghasilkan produk bagi sesebuah syarikat dan ini bermakna ia tidak

menghasilkan wang, oleh itu masa yang diambil untuk menjalankan perkhidmatan

penyelenggaraan pencegahan perlu menjadi lebih bermakna dan memberi manfaat

kepada syarikat. Penyelenggaraan pencegahan adalah perkhidmatan yang dilakukan

oleh kakitangan yang terlatih untuk memastikan peralatan itu dikekalkan dalam

keadaan yang memuaskan.

Penyelenggaraan pencegahan adalah satu tindakan pencegahan diambil berdasarkan

jadual yang dirancang sama ada berdasarkan masa atau pada kaunter tertentu untuk

menghalang terjadinya kerosakan yang kekal. Contoh Penyelenggaraan Pencegahan

adalah seperti menukar bearing pada setiap tahun atau servis penapis udara pada

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setiap 50,000 jam mesin operasi. Penyelenggaraan berjadual biasanya berdasarkan

saranan vendor peralatan, dan melalui pengalaman selama mengendalikan peralatan

ini. Jurutera-jurutera akan mengubahsuai jadual berdasarkan jangka hayat terdekat

sebenar yang diperolehi dari sejarah mesin tersebut.

Pembuatan sel suria menghadapi masalah mesin rosak yg tidak dijangka yang

tinggi. Tujuan projek ini adalah untuk membina Penyelenggaraan Jangkaan dengan

menggunakan Pemantauan Kondisi dalam mesin pembuatan sel suria kerana tidak

semua jenis masalah boleh diselesaikan atau dicegah dengan sistem

penyelenggaraan berjadual. Mesin mempunyai pelbagai faktor penyebab seperti

parameter proses yang terlibat dan juga faktor campur tangan manusia. Tindakan

pencegahan perlu dilakukan sebelum mesin itu rosak. Walau bagaimanapun,

penyelenggaraan pencegahan yang berjadual adalah sekurang-kurangnya perkara

yang perlu untuk mengurangkan kerosakan mesin jika tiada penyelesaian yang lain.

Kajian ini telah mencadangkan untuk menggunakan kaedah Program

Penambahbaikan Berterusan oleh Vannest dan Wassenhove yang dibina pada tahun

1995 yang bertujuan untuk mengurangkan masalah mesin. Kajian ini telah

mencadangkan garis arus dan alat yang menyeluruh untuk program

penambahbaikan yang berterusan ini dengan penggunaan Analisis Pareto dan

FMEA sebelum memulakan aktiviti peningkatan. Kajian ini juga telah

membangunkan satu kaedah spontan diagnostik Penyelenggaraan Sistem Jangkaan

yang telah dibangunkan Groba et al. pada tahun 2007. Ini Penyelenggaraan Sistem

Jangkaan telah dibangunkan menggunakan kaedah diagnostik melalui penggunaan

had-had kegagalan dan had-had ambang.

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Penyelenggaraan Sistem Jangkaan ini telah dibangunkan dan diuji di sebuah syarikat

pembuatan sel solar di Semenanjung Malaysia yang baru sahaja beroperasi dalam

tempoh kurang dari 5 tahun. Ia telah disahkan bahawa Penyenggaraan Sistem Jangkaan

ini telah menyebabkan pengurangan masalah mesin lebih daripada 23% untuk mesin-

mesin Pemendapan dan mesin-mesin Resapan di dalam sebuah syarikat pengilangan

Sel Suria. Kajian ini telah berjaya menghasilkan garis arus dan alat yang menyeluruh

untuk program Penambahbaikan yang Berterusan ini yang digabungkan dengan

pembentukan Penyelenggaraan Sistem Jangkaan yang menggunakan had-had

kegagalan dan had-had ambang.

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I certify that an Examination Committee has met on January 16, 2013 to

conduct the final examination of Nurhaiza Shahrir on her Master of Science

thesis entitled “Development and Verification of Predictive Maintenance

System in a Solar Cell Manufacturing Industry.” in accordance with Universiti

Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian

Malaysia (Higher Degree) Regulations 1981. The Committee recommends that

the student be awarded the relevant degree.

Member of the Examination Committee were as follows:

Zulkiflle Leman, PhD

Professor Madya

Faculty of Engineering

Universiti Putra Malaysia (Chairman)

Faiezah Abdul Aziz, PhD

Professor Madya

Faculty of Engineering

Universiti Putra Malaysia (Internal Examiner)

Shamsuddin Sulaiman, PhD

Y. Bhg. Professor

Faculty of Engineering

Universiti Putra Malaysia (Internal Examiner)

Khalid Hasnan, PhD

Professor Madya

Faculty of Engineering

Universiti Tun Hussein Onn Malaysia (External Examiner)

SEOW HENG FONG, PhD

Professor and Deputy Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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This thesis was submitted to the senate of Universiti Putra Malaysia and has

been accepted as fulfillment of the requirement for the degree of Master of

Science. The members of the supervisory committee were as follow:

Mohd Khairol Anuar Mohd Ariffin, PhD

Associate Professor

Faculty of Engineering

Universiti Putra Malaysia

(Chairman)

Napsiah bt Ismail, PhD

Professor

Faculty of Engineering Universiti Putra Malaysia (Member)

Tang Sai Hong, PhD

Associate Professor

Faculty of Engineering Universiti Putra Malaysia (Member)

BUJANG BIN KIM HUAT, PhD

Professor and Dean

School of Graduate Studies

Universiti Putra Malaysia

Date:

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DECLARATION

I declare that this thesis is my original work except for quotations and

citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at Universiti

Putra Malaysia or other institutions.

NURHAIZA SHAHRIR

Date: 16 January 2013

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TABLE OF CONTENTS

Page

ABSTRACT ii

ABSTRAK v

APPROVAL viii

DECLARATION x

LIST OF FIGURE xiii

LIST OF TABLES xvi

LIST OF ABBREVIATION xvii

CHAPTER

1 INTRODUCTION

1.1 Background 1

1.2 Problem Statement 3

1.3 Research Objectives 6

1.4 Scope and Limitation 7

1.5 Significance of Study 7

1.6 Overview of this Research 8

1.7 Thesis Structure 9

2 LITERATURE REVIEW 2.1 Types of Maintenance 10

2.1.1 Reactive Maintenance 11

2.1.2 Preventive Maintenance 11

2.1.3 Predictive Maintenance 14

2.1.4 Proactive Maintenance 20

2.2 Effective Decision Approach 21

2.2.1 Pareto Analysis 21

2.2.2 Root Cause Analysis 24

2.2.3 FMEA 25

2.2.4 Recommend Actions for Solutions 27

2.2.5 Critical Review of Effective Tools 27

2.3 Standard Operating Procedure 28

2.4 Development of Predictive Maintenance System based on Researchers 28

2.4.1 Critical Review of Predictive Maintenance System 35

2.5 Summary 37

3 METHODOLOGY

3.1 Research Methodology 38

3.2 Streamline and Comprehensive tools for Continuous Improvement

Program 41

3.3 Predictive Maintenance System and Diagnostic Methodology 42

3.4 Overall Process Flow Chart 44

3.4.1 Using Streamline and Comprehensive tools for Continuous

Improvement Program 46

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4 DEVELOPMENT OF PREDICTIVE MAINTENANCE SYSTEM

4.1 Predictive Maintenance System Development 47

4.1.1 Identification of Indicator 48

4.1.2 Measurement of Indicator 48

4.1.3 Modeling of Indicator 48

4.1.4 Forecasting of Indicator 50

4.1.5 Decision Making 50

4.2 Predictive Maintenance System Verification 51

5 RESULT AND DISCUSSION

5.1 Introduction 51

5.2 Case Study Limitation 51

5.3 Case Study Introduction 52

5.3.1 Obtain clear picture of Equipment Performances 54

5.3.2 Pareto Analysis of Historical Equipment Failures 57

5.3.3 FMEA on Top Failure(s) 59

5.3.4 Development of Predictive Maintenance System 64

5.3.5 Document in Standard Operating Procedure (SOP) 84

5.3.6 Verification of Predictive Maintenance System 84

5.4 Summary 90

6 CONCLUSION AND RECOMMENDATION

6.1 Conclusion 91

6.2 Recommendation 92

REFERENCES 93

APPENDICES 98

BIODATA OF STUDENT 115

LIF OF PUBLICATIONS 116